Method of forming a vehicle window frame with a seal insert

ABSTRACT

A vehicle tilt-out window with a resilient seal insert includes an annular frame which is bonded to the vehicle window opening. The frame includes a resilient double lip seal which is molded into a recess formed in the frame and the lip seal cooperates with a glass panel mounted upon the frame by homogeneous hinge tabs extending from the frame permitting the glass panel to be tilted relative to the frame for ventilation purposes and an articulated pivoting latch mounted to a homogeneous latch base locks the glass panel against the lip seal.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention pertains to the method of forming a vehicle tilt-outwindow of a synthetic plastic material by molding wherein a resilientlip seal is molded within a pre-formed frame to form an intregalassembly. Homogeneous hinge tabs are defined upon the frame forsupporting a glass panel which sealingly engages the seal and a linkageoperator is used to hold the glass panel against the seal, and tilt thewindow outwardly for ventilation purposes.

2. Description of the Related Art

Vehicles, particularly pickup truck cabs and vans, often use a tilt-outwindow for ventilation purposes.

Such tilt-out windows are usually formed by attaching a glass panel bymeans of pivoting or spring type hinges riveted or bolted to the vehiclesheet metal construction. A glass panel is connected at the forward edgeof the panel to the window frame by the hinge structure, and the rearedge of the glass panel is pivoted inwardly and outwardly by means of aover-center linkage mechanism, the base of which is riveted or bolted tothe vehicle sheet metal structure. The window is maintained in itslocked position, and in its extended venting position, by the linkage.

A water tight seal between the glass panel and the window frame isachieved by a resilient seal mounted upon the edges of the windowopening in the vehicle body. The seal is formed of a resilient rubber orrubber-like material, and is usually bonded directly to the outervehicle body adjacent to the opening by adhesives, or is framed in sucha way as to permit it to be slipped over the edges of the window openingand retained without adhesives.

Tilt-out windows of the aforedescribed type are expensive to manufactureand assemble in that the assembly of the seal to the window openingrequires the application of adhesive to the seal, or careful applicationof a seal or an accurate assembly of a seal designed to slip over theopening edge. Also, this type of tilt-out window is subject to sealfailure in the event the seal "pops out" of the frame recess due to thefailure of the adhesive or the slip-over retention. This type of sealalso includes a joint at the two ends of the extruded seal, presenting aleak path.

Further, conventional vehicle tilt-out windows require expensive hingestructure and assembly techniques, and often include "custom" placing ofthe hinges and latch base in order to compensate for irregularities inthe sheet metal structure, and such assembly costs significantly add tothe expense of the finished product.

SUMMARY OF THE INVENTION

It is an object of the invention to provide a method for forming avehicle tilt-out window module wherein a resilient seal is molded into arecess defined in a pre-formed frame.

Another object of the invention is to provide a vehicle tilt-out windowframe formed of a substantially rigid synthetic plastic material whereina flexible elastic seal is molded into the frame to form an intregalassembly whose seal is continuous or "jointless".

Yet another object of the invention is to provide a vehicle tilt-outwindow frame of substantially rigid synthetic plastic material having aresilient flexible seal molded therein, and frame holes receiving theseal material aid in the retention of the seal within the frame.

A further object of the invention is to provide a vehicle tilt-out framewhich includes homogeneously molded hinge tabs and a latch base,eliminating the need for separate hinge and latch base components.

In the practice of the invention, an annular semi-rigid syntheticplastic frame is injection molded of a configuration as desired. Theframe configuration includes an outwardly facing recess extending aboutthe entire configuration of the frame, and upon its inner side the framewill include recesses and other configurations for receiving bondingmaterial, or seals, for attaching the frame to the vehicle opening. Therecess formed in the frame outer side includes a plurality of sprueholes intersecting the frame inner side and recess whereby the sealmaterial may be injected into the recess.

After the semi-rigid window frame is formed and removed from its mold,the frame is inserted into another set of injection molding dies and aresilient flexible seal material is injected into the frame recessthrough the sprue holes. The dies include thin recesses for forming adouble lip seal extending from the frame recess which diverge outwardly.In this manner, a flexible double lip seal is intregally assembled tothe frame and an intimate contact occurs between the seal and frame dueto the mold-in-place that has occurred in defining the seal. As the sealmaterial is located within the sprue holes, the sprue holes also aid inretaining the seal within its groove. Such intregal forming of the sealand frame eliminates subsequent assembly procedures reducing assemblycosts, as well as providing a superior seal and frame assembly.

The modular assembly is attached to the vehicle sheet metal structure ina closed position by use of adhesives wherein the optimum sealingposition of the glass panel in its cooperation with the resilient doublelip seal is maintained during the bonding process, allowing the bondingmaterial to compensate for sheet metal irregularities. In this way thesheet metal irregularities are prevented from being transferred to theseal, compromising the seal between the seal lips and the glass panel.

The frame also includes homogeneous hinge tabs which extend toward theopposite side of the frame. The glass panel associated with the frame isaffixed to the hinge tabs, and the hinge tabs, though formed of thesemi-rigid material of the frame, are capable of the limited deflectionnecessary to accommodate the movement of the glass panel between openand closed positions.

Also, the pivoted operating linkage for the window is mounted upon ahomogeneous latch support formed during the molding of the window frame.

BRIEF DESCRIPTION OF THE DRAWING

The aforementioned objects and advantages of the invention will beappreciated from the following description and accompanying drawingswherein:

FIG. 1 is an elevational view of a vehicle tilt-out window in accordwith the invention as viewed from the exterior,

FIG. 2 is an elevational view of the window frame, per se,

FIG. 3 is an enlarged detail elevational sectional view taken through ahinge tab along Section 3--3 of FIG. 1,

FIG. 4 is an enlarged elevational detail sectional view of the operatinglinkage as taken along Section 4--4 of FIG. 1, the vehicle bodystructure not being illustrated,

FIG. 5 is an enlarged detail elevational view of the window frame priorto the molding of the seal in place,

FIG. 6 is an enlarged elevational detail view of the resilient seal asreceived within the frame recess,

FIG. 7 is a detail elevational sectional view of the mold, cavity, andwindow frame formed thereby,

FIG. 8 is an elevational sectional detail view of the molds used to formthe elastic seal, the frame being located in place, and prior to theinjection of the flexible seal material, and

FIG. 9 is a view similar to FIG. 8 after the seal material has beeninjected through the sprue openings.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The tilt-out window frame of the invention is usually employed as a sidevent window in a truck cab or van body. In FIGS. 1 and 3, the vehiclesheet metal body is represented at 10 and includes a window opening 12of the desired configuration. The window frame 14 mounts within theopening 12, as later described, and a window glass panel 16 is supportedupon the window frame in a pivotal manner for movement between open andclosed positions. The glass panel 16 includes an inner side 18, an outerside 20, and is attached to the window frame hinge tabs by bolts 22.

The window frame 14 is of an annular generally rectangularconfiguration, and of course, is shaped to conform to the window opening12 defined in the vehicle body. The window frame 14 is injection molded,as later described, and is formed of a thermoplastic such as reinforcedpolyethylene, polyester, polyamide, etc. wherein the frame is of asubstantially rigid character. Preferably, the reinforcement comprises aminimum of 30% glass by volume. The frame includes a forward lateralside 24, FIG. 2, and a rear lateral side 26, disposed toward the rear ofthe associated vehicle. The upper end of the frame is referenced at 28,while the lower end 30 interconnects the lower ends of the frame lateralportions. The frame includes an outer side 32 disposed toward the glasspanel 16, and an inner side 34 disposed toward the vehicle body andwindow opening 12.

A recess 36 is defined in the frame inner side throughout the frameconfiguration, and an adhesive 35, such as Santaprenes or other urethaneadhesive, received within recess 36 attaches the window frame 14 uponthe vehicle body and within the vehicle opening 12. The window frameincludes an extension 38, FIG. 3, which is disposed adjacent the windowopening 12 to cover or "dress" the edges of the window opening.

A recess 42 is defined in the window frame outer side 32, and aplurality of sprue holes 44 intersect the recess and the frame innerside 34 as will be appreciated from FIGS. 3-6. The sprue holes arecountersunk at 46.

As later described, a flexible resilient seal 48 formed of a rubber typematerial such as thermoplastic rubber, or other thermoplastic or curetype elastomer, is located within recess 42, and the seal includes aseal base 50 filling the recess 42. A sprue stem 52 extends from thebase 50 into the holes 44 and countersunk or counterbored portions 46,and the seal includes outwardly extending lips 54 which diverge awayfrom each other in the outward direction and intersect at the concaveintersection 56, FIG. 6. The lips 54 are flexible and directly engagewith the glass panel 16 as appreciated from FIG. 3. The lips as engagedwith the glass panel are disposed in such a way that the exposed areasopposite the glass cause the lips to engage more forcefully with theglass in the presence of a positive pressure differential from itsrespective side on the seal.

A pair of hinge tabs 58 are homogeneously defined on the window frameforward side 24, FIGS. 2 and 3, and extend toward side 26. The hingetabs each include an offset portion 60, FIG. 3, which aids in theflexing of the hinge tabs, and each hinge tab is provided with a hole 62for receiving a hinge bolt 22. In this manner, the glass panel 16 isattached to the window frame 14 in a hinged or pivotal manner at theforward edge of the glass panel with respect to the direction of vehicletravel.

A latch base 64 is homogeneously defined on the window frame rear side26, FIGS. 2 and 4, and the latch base 64 includes a pin portion 66extending between the legs of the latch, FIG. 2. A link 68 is hinged tothe pin 66, and the link 68 is pivotally attached to the handle 70, FIG.4. The handle 70 is pivotally mounted by pivot 72 to the anchor 74 whichis bonded to the glass panel inner side 18, or attached by screwsthrough a hole in the glass, FIG. 4. The latch base 64, link 68, andhandle 70 constitute an over-center linkage well known in this type ofinstallation whereby the handle 70 may be pivoted in such a manner as todraw the rear portion of the glass panel 16 toward the window frame rearlateral side 26 such that the glass inner side 18 will engage and deformthe seal lips 54 in the manner shown in FIG. 3. The glass panel 16 maybe tilted opened by pivoting the handle 70 in the opposite directionseparating the rear portion of the glass panel from the rear portion ofthe window frame seal lips 54. The degree of movement of the glass panelbetween its opened and closed positions is limited, usually in theneighborhood of two inches.

The pivots of the link 68 and handle 70 are such that an over-centerrelationship exists when the handle is pivoted to its open and closedpositions to thereby "lock" the glass panel in its open and closedconditions.

An important aspect of the invention lies in the assembly of the seal 48to the window frame 14. In accord with the invention, the seal is moldedwithin the window frame so as to eliminate any secondary assemblyoperations. The "molded-in-place" method also allows the seal to bemolded without gaps or joints, and perfectly shaped to conform to therequired configuration. The method of forming the window frame is bestappreciated from FIGS. 7-9.

In FIG. 7, an upper injection mold die is represented at 76 while thelower die is shown at 78. A cavity 80 is defined in the lower die 78corresponding to the frame inner side 34, and the upper die 76 includesa projection 82 for forming the window frame recess 42. A plurality oflower die mounted cylindrical projections 84 align with the projection82 to form the sprue and retention holes 44. Accordingly, the windowframe, including the hinge tabs 58 and the latch base 64 is injectionmolded within the dies 76 and 78.

After the window frame has cooled, the window frame 14 is removed fromdies 76 and 78 and is located within a complementary recess definedbetween an upper injection mold die 86 and a lower die 88. The lower die88 includes a sprue passage 90 in alignment with the window frame sprueholes 44, and the upper die 86 is formed with thin recesses or portions92 which form the seal lips 54. A valley 94 is defined in the die 86 forforming the concave lip intersection between the lips 54.

Upon the window frame 14 being located within the dies 86 and 88, theflexible thermoplastic material forming the seal 48 is injected throughthe sprue passages 90 and the sprue holes 44 into the recess 42 and thepassages 90. In this manner, the seal 48 is formed in place within thewindow frame recess 42, and upon removal of the window frame and sealassembly shown in FIG. 9 from the die halves 86 and 88, the sprue issevered at the countersink 46, and the assembly of the window frame andseal is completed. During the injection molding and formation of theseal 48 some of the holes 44 are used to aid in the venting of air andentrapped gases during the injection molding.

The molding of the seal 48 into the window frame recess 42 eliminatessecondary assembly procedures, produces superior bonding and attachmentbetween the seal and window frame, and results in a superior product ascompared to window frames wherein the seal structure is separatelyassembled thereto. In addition to the bonding that may occur between theseal material and window frame within recess 42, the presence of theseal material within the sprue holes 44, and in the countersinks 46further aids in resisting removal of the seal from the window frame.

It is appreciated that various modifications to the inventive conceptsmay be apparent to those skilled in the art without departing from thespirit and scope of the invention.

We claim:
 1. The method of forming a vehicle window frame of moldablesynthetic plastic having an integral resilient lip seal, the framesupporting a glass panel pivotal relative to the frame between open andclosed positions and sealed to the frame by the lip seal in the closedposition, comprising the steps of:(a) molding a frame of a substantiallyrigid synthetic plastic material in a first mold to define a frameperiphery having an outer side and an elongated recess defined in theouter side, a plurality of sprue holes being defined in said frame incommunication with said recess each having an inlet end located remotelyfrom said recess, (b) removing the frame from the first mold, (c)inserting the frame in a second mold having a resilient lip sealconfiguration cavity in alignment and communication with the framerecess, (d) injecting a flexible seal material into said recess andcavity through said sprue holes to define a flexible lip seal extendingfrom the frame recess and outer side, said flexible seal materialfilling said sprue holes, (e) cooling said flexible seal, (f) removingthe integrated frame and seal from said second mold, and (g) severingsaid seal material adjacent said sprue hole inlet ends whereby the sealmaterial within said sprue holes aids in retaining said seal within saidrecess.
 2. The method of forming a vehicle window frame as in claim 1wherein said seal configuration cavity includes a pair of thin portionsobliquely angularly related to each other whereby the formed sealincludes a pair of flexible sealing lips as defined by said thinportions.